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Publication numberUS3673617 A
Publication typeGrant
Publication dateJul 4, 1972
Filing dateSep 16, 1969
Priority dateSep 16, 1969
Publication numberUS 3673617 A, US 3673617A, US-A-3673617, US3673617 A, US3673617A
InventorsRobert D Schulz Jr
Original AssigneeRobert D Schulz Jr
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Integral tops and bowls for sinks and the like and methods of making the same
US 3673617 A
Abstract
An integral sink top and bowl structure and method of making the same are provided having an outer layer of rigid resin reinforced with fibers and an inner layer of substantially greater thickness of a foamed in situ resin fixed to said outer layer, said foamed resin having a density between about 5 to 20 lbs per cubic foot and a dense, hard skin on the exposed surfaces thereof.
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Description  (OCR text may contain errors)

United States Patent 1151 3,673,617 Schulz, Jr. July 4, 1972 541 INTEGRAL TOPS AND BOWLS FOR 3,255,061 6/1966 Dobbs ..156/79 SINKS AND THE LIKE AND METHODS 3,391,823 7/1968 Tijms ..220/83 OF MAKING THE SAME 3,433,860 3/1969 Ruggles et al ..264/71 72 Inventor: Robert D. Schulz, Jr., 1386 Cardial Drive, FOREIGN PATENTS 0R APPLICATIONS Pittsburgh, 15243 1,212,667 10/1959 France ..187/ 22 Ffled: Sept 1 19 9 l,227,969 3/1960 France ..4/173 [21] Appl.No.: 858,369 Primary Examiner-Laverne D. Geiger Assistant Examiner-Donald B. Massenberg (52] us. c1 ..4/187 B|enk z'esenhe'm I51] Int. Cl. [58] Field of Search ..4/187, 166, 173;264/71,45 1 ABSTRACT An integral sink top and bowl structure and method of making 6 References Cited the same are provided having an outer layer of rigid resin reinforced with fibers and an inner layer of substantially greater UNITED STATES PATENTS thickness of a foamed in situ resin fixed to said outer layer, said foamed resin having a density between about 5 to 20 lbs 3,045,254 7/1962 Cook et a1. ..4/ 173 rf 3,120,570 2/1964 Kennedy et al. ..264/45 3,1123? and a dense hard 8km the posed aces 3,220,902 11/1965 Edwards ..156/79 3,231,439 1/1966 Voelker 156/79 7 Claims, 3 Drawing Figures PKTENTEDJHL 4 1972 v 3. 673 6 1 7 sum 1 BF 2 INVENTOR Robert D. Schulz, Jr.

PATENTEnJuL'Ms-izz 3,673,617

' suwznrz INVENTOR INTEGRAL TOPS AND BOWLS FOR SINKS AND THE LIKE AND METHODS OF MAKING THE SAME This invention relates to integral tops and bowls for sinks and the like and methods of making the same and particularly to an integral top and bowl structure made of plastic foam and reinforced rigid plastic and particularly of urethane type foam in combination with glass fibers and rigid resin.

The manufacture of sink tops to which bowls are later attached is a practice which is quite old. These sink tops have been formed of laminates covered with an outer protective sheet of formica or the like plastic capable of resisting stains and ordinary household liquids. Integral sink tops and bowls have also been cast of various mixtures of aggregate and binder including marble chips in various siliceous cements and in a variety of dense plastic materials. None of these structures has been entirely satisfactory for a variety of reasons known to the trade. In the laminate structures there always exists the problem of forming a satisfactory seal between the top and bowl as well as the problems of skin damage and penetration which are inherent in the thin skin covering and warpage of the base. In the case of the integral cast tops and bowls of aggregate and binder, the structures are too heavy, too brittle, too easily damaged and could only be satisfactorily fabricated in small units.

The present invention eliminates these problems and makes possible the casting of integral tops and bowls in any size and shape desired. The present invention provides a structure which is relatively light in weight, very strong and resistant to damage and easily formed.

Preferably the invention provides an outer layer of fiber glass reinforced resin such as polyester, epoxy or the like and a backing layer of controlled thickness and density formed of a foamed polyol such as polyester or polyether with isocyanate, a blowing agent, surfactant and catalyst. Preferably the foamed backing is of a density in the range of about 2 to 20 lbs per cubic foot and particularly about 5 lbs per cubic foot and is fonned in a closed mold to provide a hard impenetrable outside skin. Preferably the outer surface of fiber glass reinforced resin contains whatever color and design characteristics are desired.

In the foregoing general description certain objects, purposes and advantages of this invention are set out. Other objects, purposes and advantages will be apparent from a consideration of the following description and the accompanying drawings in which:

FIG. 1 is an isometric view of an integral sink top and bowl according to the present invention;

FIG. 2 is a section on the line lI-II of FIG. I; and

FIG. 3 is an exploded view of a mold for making sink tops and bowls according to this invention.

Referring to the drawings an integral sink bowl and top are provided having an outer layer, both top and bottom, formed of glass fibers embedded in and reinforcing an outer surface of rigid resin such as polyester resin 11. The rigid resin 11 may be an epoxy resin or any other of the well-known rigid resins used in fiber glass resin molding systems. A back-up layer 12 of substantially greater thickness than the fiber glassresin layer 10-11 is formed of foamed in situ urethane or similar plastic foam. The foam layer I2 may be made by reacting a polyol with isocyanate in the presence of a blowing agent such as Freon or water or a combination thereof together with the necessary catalyst and surfactant to produce a desired strength, density and surface condition. A typical foam composition may be based upon the combination described in Technical Bulletin 101 of The Upjohn Company, Polymer Chemicals Division, Kalamazoo, Michigan at pages 5 and 6.

The sink top and bowl of this invention are preferably made by placing a preformed plastic overflow tube 13 having end connections 14 and 15 in place in a mold 16. An outer layer of 5 fiber glass reinforced resin 11 is sprayed in place on both mold I6 and mold 17 using chopped fiber glass. This layer could be laid up by hand or otherwise applied to the mold but spraying is preferred. A mixture of polyol, isocyanate, surfactant and catalyst is poured into mold 16 on top of the resin layer 11 and 10 covered with mold cover 17 and the resin layer therein. Alternatively the mixture could be poured into the mold through opening 18 in mold cover 17 and the opening closed. The polyol is permitted to foam in situ in the closed mold to form a rigid foamed layer 12 having a density of about 5 pounds per 1 5 cubic foot which is firmly adhered by its inherent adhesiveness to the two glass-resin layers I0-l1. The mold cover 17 is removed and the completed sinkbowl and top removed from mold 16.

The sink top and bowl of this invention is highly resistant to 20 stains and surface damage, is quite rigid, has great strength and is light in weight and easily handled. It is free of all of the defects which have been prevalent in this art.

While a preferred embodiment and practice of this invention have been described in the foregoing specification it will be understood that this invention may be otherwise embodied and practiced within the scope of the following claims.

lclaim: 1. An integral sink top and bowl structure comprising an outer layer of rigid resin reinforced with fibers, and an inner layer of substantially greater thickness of a foamed in situ resin fixed by its inherent adhesiveness to said outer layer, said foamed resin having a density between about 2 to 20 lbs per cubic foot and a dense, hard skin on the exposed surfaces thereof.

2. An integral sink top and bowl structure as claimed in claim 1 wherein the outer layer is composed of fiber glass reinforced resin from the group consisting of polyester resin and epoxy resin.

3. An integral sink top and bowl structure as claimed in claim 1 wherein the foamed in situ resin is urethane.

4. An integral sink top and bowl structure as claimed in claim 2 where in the foamed in situ resin is fonned of a polyol from the group polyester and polyether, an isocyanate, a surfactant and a catalyst.

S. An integral sink top and bowl structure as claimed in claim I having a preformed plastic tube formed therein as an overflow drain.

6. The method of forming an integral sink top and bowl comprising the steps of:

a. applying a layer of rigid resin and fibers to the inner surfaces of a mold,

b. closing said mold,

c. foaming in said closed mold a composition capable of forming a foam of a density between about 2 and 20 lbs. per cubic foot with a high density non-porous skin and adhered to the resin, and

d. setting said foam in said mold and thereafter removing the formed top and bowl.

7. The method of forming an integral sink top and bowl 6() comprising the steps of:

a. forming a top and bottom shell of fiberglass and resin,

b. placing said top and bottom in spaced relation to form a hollow core,

0. foaming a resin within said spaced top and bottom having a density in the range of 2 to 20 lbs per cubic foot.

Patent Citations
Cited PatentFiling datePublication dateApplicantTitle
US3045254 *May 5, 1961Jul 24, 1962Robert G CookBathtub with liner
US3120570 *Apr 20, 1961Feb 4, 1964Southern California Plastic CoProcess for forming an insulated container
US3220902 *May 5, 1964Nov 30, 1965Illinois Tool WorksLaminated container forming method and apparatus
US3231439 *Nov 27, 1962Jan 25, 1966Allied ChemDimensional stabilization of foam panels
US3255061 *Apr 20, 1962Jun 7, 1966Us Rubber CoProcess for making synthetic leather-like material
US3391823 *Mar 2, 1965Jul 9, 1968Vasco Ind CorpRigidified polyethene structures and method of producing them
US3433860 *Dec 30, 1966Mar 18, 1969American Standard IncMethod for manufacturing a sink and vanity top combination
FR1212667A * Title not available
FR1227969A * Title not available
Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US3855647 *Nov 5, 1973Dec 24, 1974Inter DyneCup sink for laboratory counter tops
US4053545 *Jul 29, 1975Oct 11, 1977Standard Oil Company (Indiana)Process for manufacturing laminated structural foam articles
US4110851 *Dec 15, 1976Sep 5, 1978Bernard RapatelSanitary appliance
US4209862 *Mar 22, 1979Jul 1, 1980Cortes Garza RodrigoBathroom fixtures and process of manufacture
US4328179 *Apr 7, 1980May 4, 1982Gruber Systems, Inc.Method for making a cast toilet base of plastics material
US4383955 *Aug 24, 1981May 17, 1983Marcelino RubioProcess for fabricating a closed, foam-filled, reinforced polyester resin shell article
US4938825 *Jul 12, 1989Jul 3, 1990Armitage Shanks LimitedProcess for manufacturing laminated bath tub or shower tray
US4948541 *Oct 27, 1988Aug 14, 1990Stephen BeckMethod of forming an arm rest for a chair having a tubular passageway for containing control mechanisms
US5948333 *May 21, 1998Sep 7, 1999Replica PlasticsMethod for creating imitation marble facade for objects
US7278176 *May 30, 2002Oct 9, 2007Clarke Products, Inc.Fiberglass reinforced fixture with finished polymeric cap
US20100175182 *Jun 9, 2008Jul 15, 2010Cleanup CorporationManufacturing process of work top with sink
US20100294004 *Jan 12, 2009Nov 25, 2010Jiebo HuMultifunctional integrated cleaner unit machine
Classifications
U.S. Classification4/631, 264/261, 4/650, 264/46.6, 264/46.9, 264/309, 4/DIG.900
International ClassificationB29C44/12, E03C1/18
Cooperative ClassificationB29L2031/7698, E03C1/18, B29C44/12, Y10S4/09
European ClassificationE03C1/18, B29C44/12